Porous materials are widely employed in a wide variety of industrial applications due to their advanced functional performance. Porous aluminum is among the most attractive metallic materials. It can be produced using repeatable methods involving a replicated Al foam that also provides porosity control. In this work, a highly porous replicated Al foam was fabricated. First, the model of multifunctional packing density was used and corrected to select the appropriate space holders. Then, Al foam was produced using a double-granular sodium chloride space holder. The obtained results showed a maximum porosity of 65% that was achieved using a mix of coarse, irregular granules with spherical granules of intermediate size.
Keywords: Al alloy; packing density model; porosity; replicated foam; space holder; vacuum casting.